IVA fixes: fuel line, number plate, indicators

 The easy one first, the number plate. Now the new mount is on the number plate sits in the right place and there are no sharp edges. It's ugly, but it's not sharp;

Fuel lines was also successful, as mentioned earlier the main battle was going to be drilling the holes and fitting the rivnuts. Once that was done I could prototype the straps with cardboard;

Then cut and drill the appropriate steel version. As it's steel rather than aluminium, they needed a coat of paint before applying, but I think they've gone on really well;

Because they're rivnuts rather than through bolts with nylocs I applied a drop of threadlock to them. I don't want the bolts falling off before I get back to the test centre!! Of course, threadlock plus rivnut is not a good idea at the best of times but with any luck these won't need removing at all. There is a good fingers worth of gap all round the pipe as it goes past the mount, it's also going through the largest gap possible which is next to the rubber. 

So that's two jobs ticked off and now the car can be put back on the ground. And guess what... the indicators are still too low!

The illuminated surface (which is what is measured) is a few mm lower than is required. I suspect Mr IVA would be fine with it, but to remove doubt I'm combining this approach with the original suggestion of masking off half the light. I currently have the lenses sat behind me, getting multiple coats of paint to block the lower half. I also 3D printed an internal shield again to cover half, but that leaked too much light. I'll still use it, in combination with the paint. Again, probably overkill but it removes doubt.

Oh, and I need to replace the screws with IVA friendly bolts. 

Last one, the new clutch cylinder went on, and with it depressed it clears the brake pipe;

It does feel a lot better than the old one too, the old one used to get 'stuck' every so often. Not enough to be a worry but enough to feel in the pedal. The only thing I want to look at is the pedal travel though, I'm still getting some issues with clutch disengagement. If I can adjust my clutch pedal slightly I'll see if I can get it to operate a bit further. Of course that will depend on whether I put any adjustment into the clutch lever!

The new brakes are on, I'm still waiting for Royal Snail to deliver the brake carrier bolts that I want to replace but hopefully that won't be too long. I did see an interesting way of adjusting the handbrake though.

Normally to adjust the handbrake you turn the caliper adjuster until it locks, then back it off a 'tad'. I say 'tad', because there doesn't seem to be a consistent value that it's turned. I got it somehow right the first time but far more luck than judgement.

The other way is to lift the handbrake a couple of clicks, then 'snug up' the adjuster. That way when you release the handbrake it ends up being in the right place on both sides. This approach appeals to me much more as it relies on fixed end points rather than a vague 'that will do'. I'm going to try that tonight. There are a couple of views on how many clicks though, one video suggests two and the other says six. I'll try two first, if that doesn't give me smooth running brakes then I'll try six.

So a quick recap, here is my failure sheet;

1. Exhaust fixings. Done
2. Rear number plate mount. Done
3. Direction indicators. A couple more coats of paint and screws replaced.
4. Design weights. Updated.
5. Clutch fork. Done.
6. Fuel pipe. Done. 

So once the indicators are done and the bolts arrive I'll get it booked in. And then a few weeks later will be a licence plate request with the DVLA! 

(Quick update)

The handbrake is now adjusted, it is so much easier to do it with the handbrake on and 'snugged up'. It's nice and even both sides and hopefully a bit of a run will be enough just to take the surface off the discs. 

The clutch cylinder is adjustable but I won't do that just yet. It needs a bit of yoga to get to the right place and it's been a busy day. The caliper bolts also arrived so they're fitted and torqued up, and the new sticker for the brake fluid is stuck on. 

I've also bought some heat set inserts for the lights. I can't figure out how to get nuts to the back of the light fitting, but the brass fittings that are used for mechanical prints will work very well here. Once they arrive tomorrow I'll fit the lenses now they're painted. The paint did work, there's no light coming out below halfway so it's definitely meeting the requirement.